Machining process information

                                                        Machining

Introduction :- machining is the most important of the manufacturing processes. Machining can be defined as the process of removing material from a workpiece in the form of chips. The term metal cutting is used when the material is metallic. Most machining has very low set-up cost compared to forming, molding, and casting processes. However, machining is much more expensive for high volumes. Machining is necessary where tight tolerances on dimensions and finishes are required.


                 Different Types of Machining Operations :- Three primary machining processes — turning, drilling, and milling — are used as a means of removal. Each process plays a key role in how a product is manufactured and enhances each product’s unique properties...

1)Turning process:-Turning is a machining process performed by a device called a lathe; the lathe spins the given product as the blades cut and scrape away the desired areas. The cutting tools work along two axes of motion to create cuts with precise depth and diameter. Lathes are available in two different types, the traditional, manual type and the automated, computer numerical controlled (CNC) type.
                                                      The turning process can be performed on either the exterior or interior of a material. When performed on the inside, it is known as "boring”—this method is most commonly applied to create tubular components. Another part of the turning process is called "facing” and occurs when the cutting tool moves across the end of the work piece—it is typically performed during the first and last stages of the turning process. Facing can only be applied if the lathe features a fitted cross-slide..

2) Driling process :-Drilling occurs when cylindrical holes are produced in a piece of solid material using a drill bit—it is one of the most important machining processes as the holes that are created are often intended to aid in assembly—to ensure stability and precision, a drill press is often used.

                    The drill bits used feature two spiral channels that run up the shaft of the bit. Known as the "fluting," it carries the chips, or swarf, out of the hole as the bit progresses into the piece of material. For each type of material, there is a recommended drill speed and feed..

3)milling process :-Milling is another process that uses rotating cutters to remove material, but the difference lies in how the equipment works. A milling machine features a moveable table on which the material is mounted. In most milling machines, the cutting tools are stationary and the table moves the material so that the desired cuts can be made. Other types of milling machines feature both table and cutting tools as moveable implements.
                         Some of the operations a milling machine is capable of performing include planing, cutting, rebating, routing, die-sinking and other complex tool-paths, making the milling machine one of the more flexible pieces of equipment in a machine shop.
                           Milling machines offer versatile operations and maintenance is low-cost; since they generally have a long and glitch-free life, the investment return is high. There are four types of milling machines—hand milling machines, plain milling machines, universal milling machines, and omniversal milling machines—and they feature either horizontal cutters or cutters installed on a vertical axis.. As expected, the universal milling machine allows for both vertical and horizontal mounted cutting tools, making it one of the most complex and flexible milling machines available

Advantage of machining Processes :-  1) A high surface finish can be obtained.
2) Machining is not only performed on the metal but it also performs on wood, plastic, composites, and ceramics.
3) Variety of geometry features are possible, such a Screw threads, Very straight edges, Accurate round holes etc.
4) Good dimensional accuracy.

Limitations of machining processes :-
1) The accuracy of the components produce is dependent on the efficiency of the operator.
2) The consistency in manufacturing is not present. Hence 100% inspection of the component is required.
3) The personal needs of the operator are reducing the production rates.
4) Because of a large amount of Manpower involved, the labor problem will also be high.
5) The complex shapes like parabolic Curvature components, Cubicle Curvature components are difficult to manufacture.

Other  Process :- 
1)shaping, 
2) planing,
3) boring,
4) broaching,
5) sawing.

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