MACHINING OPERATION

DRILLING, MILLING
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

MACHINING

Material removal process in which a sharp cutting tool is used

to mechanically cut away material so that the desired part
geometry remains
Most common application: metal parts
Most versatile of all manufacturing processes in its capability
to produce a diversity of part shapes and geometric features
with high precision and accuracy
Casting can also produce a variety of shapes, but it lacks the
precision and accuracy of machining
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

Drilling

Creates a round hole in a

workpart
Compare to boring which
can only enlarge an existing
hole
Cutting tool called a drill or
drill bit
Machine tool: drill press
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

THROUGH HOLE VS. BLIND HOLE

(a) Through hole - drill exits opposite side of work and (b) blind
hole drill does not exit opposite side
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

OPERATIONS RELATED TO DRILLING

(a) Reaming, (b) tapping, (c) counterboring

2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

MORE OPERATIONS RELATED TO

DRILLING

(d) Countersinking, (e) center drilling, (f) spot

facing
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

Drill Press

Upright drill press stands

on the floor
Bench drill similar but
smaller and mounted on a
table or bench
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

RADIAL DRILL PRESS

Large drill press designed

for large parts (photo
courtesy of Willis
Machinery and Tools)
BORING

Difference between boring and turning:

Boring is performed on the inside diameter of an
existing hole
Turning is performed on the outside diameter of an
existing cylinder
In effect, boring is internal turning operation

Boring machines
Horizontal or vertical - refers to the orientation of the
axis of rotation of machine spindle
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

VERTICAL BORING MILL

Applications large,
heavy workparts that
have low L/D ratio
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

WORK HOLDING FOR DRILL PRESSES

Workpart in drilling can be clamped in any of the following

workholders:
Vise - general purpose workholder with two jaws
Fixture - workholding device that is usually
customdesigned for the particular workpart
Drill jig similar to fixture but also provides a means
of guiding the tool during drilling
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

MILLING

Machining operation in which work is fed past a rotating tool

with multiple cutting edges
Axis of tool rotation is perpendicular to feed
Cutting tool called a milling cutter
Cutting edges called teeth
Machine tool called a milling machine
Interrupted cutting operation
Basic milling operation creates a planar surface
Other geometries possible
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

TWO FORMS OF MILLING

(a) Peripheral milling and (b) face milling

2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

PERIPHERAL MILLING VS. FACE MILLING

Peripheral milling
Cutter axis parallel to surface being machined
Cutting edges on outside periphery of cutter
Face milling
Cutter axis perpendicular to surface being milled
Cutting edges on both the end and outside periphery
of the cutter
 2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

TYPES OF PERIPHERAL MILLING

(a) Slab milling, (b) slotting, (c) side milling, (e) straddle milling, and
(e) form milling
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

TYPES OF FACE MILLING

(a) Conventional face milling, (b) partial face milling, (c) end
milling, and (d) profile milling using an end mill
2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

TYPES OF FACE MILLING

(e) Pocket milling and (f) contour milling

2010 John Wiley & Sons, Inc. M P Groover, Principals of Modern Manufacturing 4/e SI
Version

KNEE-AND-COLUMN MILLING
MACHINES
(a) Horizontal and (b) vertical knee-and-column milling
machines
MODERN MILLING MACHINES
MODERN MILLING MACHINES (CONTD)
EXAMPLE OF MILLING PRODUCT
PROCESS PLAN SURFACE FACING

f Facing : Surface and side

Surface CoroMill 345
Max Depth per cut = 6 mm
Page J43 or 71

p l
x a m
E
e
THE EQUATIONS

Fr = feed rate,mm/min(in/min);
N = spindle speed, rev/min;
nt = number of teeth on the
cutter;
f = chip load in mm/tooth
(in/tooth).
PROCESS PLAN SURFACE FACING CONTD

Vc Page J474 or 502. We can calculate the

spindle speed.
PROCESS PLAN SURFACE FACING CONTD

Feed per tooth

Page 526
We can
calculate the
feed.
 p l
PROCESS PLAN SIDE FACING
x a m
E
e
Square Shoulder Milling page 21 Page 308
Select from Page 352
 p l
PROCESS PLAN SIDE FACING CONTD
x a m
E
e
Cutting
Parameter
Page 518
 PROCESS PLAN SIDE FACING CONTD

Cutting Parameter Page

518

p l
x a m
E
e
Next process Page 328
LETS DEFINE

The milling process

The Tools required
Cutting Parameter
MACHINING CENTER

Highly automated machine tool that can perform

multiple machining operations under CNC
control in one setup with minimal human
attention
Typical operations are milling and drilling
Three, four, or five axes
Other features:
Automatic toolchanging
Pallet shuttles
Automatic workpart positioning
CNC MACHINING CENTER
CNC TURNING CENTER - INDUSTRIAL
ROBOT TO LOAD AND UNLOAD PARTS
 MILL-TURN CENTERS

Highly automated machine tool that can perform turning, milling,

and drilling operations in one setup
General configuration of a turning center
Can position a cylindrical workpart at a specified angle so a
rotating cutting tool (e.g., milling cutter) can machine features
into outside surface of part
Conventional turning center cannot stop workpart at a
defined angular position and does not include rotating tool
spindles
 Operation of Mill-Turn Center

(a) Part with turned, milled, and drilled

surfaces; and (b) sequence of
operations : (1) turn second diameter,
(2) mill flat, (3) drill hole, and (4) cutoff