Machining

Difference between coated and uncoated cutting tools
Machining

Machining

Cutting tool is a part and parcel in every conventional machining process. Tool material and geometry are two active parameters that influence process capability and machinability. For uninterrupted material removal, the tool material should be harder than the workpiece material. In addition to the hardness, tool material should ideally possess certain common properties, such as high strength, high toughness, high fatigue strength, shape retention capability at high temperature, high thermal

Difference between drilling and end milling
Machining

Machining

Machining is one type of manufacturing process where excess material is removed from the workpiece to impart intended shape, size and finish. It follows the principle of subtractive manufacturing approach to build 3-D components. Conventional machining processes employ a cutting tool that contain one or more shape edges, and layer by layer material is removed from the workpiece in the form of solid chips. In order to process a wide

Difference between machining and fabrication
Machining

Machining

Fabrication indicates building the desired component using one or more manufacturing processes. Manufacturing is one technical term that is defined as a step by which raw material or scrap is converted to the useful product by adding substantial values. The manufacturing step consists of seven basic processes – each of these processes once again consists of many operations. Machining is just one manufacturing process; there are many others as discussed

Difference between machine and machine tool
Machining

Machining

In the field of mechanical engineering, “Machine” is defined as an assembly of mechanisms that are clustered together in such a way that it can perform certain operations by utilizing electrical, mechanical, hydraulic and/or pneumatic power, and thereby reduces the requirement of human effort and intervention in doing the task. However, “Machine Tool” is not exactly same with the machine. The term Machine includes wide variety of machinery, whereas Machine

Difference between machine tool and cutting tool
Machining

Machining

In the field of mechanical engineering, Machine is defined as an assembly of mechanisms that are clustered together to perform certain operations by utilizing electrical, mechanical, hydraulic and/or pneumatic power. Total number of mechanisms exist within a machine may vary from just few to few hundreds! Accordingly size of a machine also varies. Some machines, irrespective of their size, are portable. For example, a hand drill (small machine) and a

Same ORS and NRS Tool Nomenclature
Machining

Machining

Geometry of the cutting tool is one crucial factor that influences overall performance (machinability) as well as productivity of machining. Thus cutting tool must be selected judiciously prior to machining based on the work material and cutting conditions. Tool signature displays various features of a cutting tool, and thus it enables quick selection of a cutting tool for specific application. There are several standard systems for designation of a single

Comparison among drilling, boring and reaming
Machining

Machining

Macro-scale hole fabrication on a solid surface requires several different metal cutting operations based on the size and accuracy requirement. One typical series for hole making can be— (i) Centering, (ii) Drilling, (iii) Boring, (iv) Reaming and (v) Honing. Centering is carried out to locate the hole for easy and accurate alignment of a drill. Although it is optional, but centering can improve precision. Drilling is a process of originating

Typical drills and reamers
Machining

Machining

In order to make a macro-scale hole on a solid surface, a series of different machining processes are carried out depending on the finish and tolerance level requirement. One typical series of hole production can be— (i) Centering, (ii) Drilling, (iii) Boring, (iv) Reaming, and (v) Honing. Centering is performed to locate the hole center, drilling is carried out to originate a hole and boring is carried out to enlarge

Images of drilling and boring tools
Machining

Machining

In order to create a hole on a solid surface, a series of different machining processes are carried out depending on the hole diameter, finish and tolerance level requirement. One typical steps for hole making can be— (i) Centering, (ii) Drilling, (iii) Boring, (iv) Reaming, and (v) Honing. Each of these processes has different objectives and can be applied under certain conditions. One operation cannot be carried out prior to

Schematic diagram of three deformation zones in machining
Machining

Machining

Machining or metal cutting is one subtractive manufacturing process that indicates layer by layer material is gradually removed from the workpiece to impart desired shape, size and finish. In conventional machining processes (such as turning, threading, milling, facing, drilling, boring, etc.), material is removed with the assistance of a wedge shaped cutting tool. Here the cutting tool compresses a thin layer of work material and gradually shears it off in

Difference between shaping and planing
Machining

Machining

Machining is basically one material removal process where excess material is sheared off by the mutual interaction between workpiece and cutting tool. There exist several machining processes to cater the need of processing a wide variety of workpiece materials in innumerable ways. For examples, lathe operations (such as straight turning, taper turning, internal turning, threading, grooving, etc.) are primarily carried out to generate cylindrical or conical surfaces. Milling operations are

Difference Between Rake Surface and Flank Surface
Machining

Machining

During machining, excess material is sheared off from the workpiece in the form of chips. A cutting tool having one or more sharp cutting edge(s) compresses a thin layer of workpiece material for shearing. This cutting edge is obtained by the intersection of rake surface and flank surface. Rake surface of a cutting tool is the chip flowing surface. That means the chips that are produced due to shearing action

Rake angle and clearance angle in machining
Machining

Machining

In conventional machining, the cutting tool compresses a thin layer of work material to gradually shear it off in the from of chip. Cutting tool is basically a wedge shaped device that actually shears off material from the workpiece. This cutting tool as well as the workpiece is mounted on the machine tool maintaining proper orientation. Necessary relative velocities between workpiece and cutter (in the form of cutting velocity, feed

Classification of rake angles positive rake negative rake and zero rake from differencebox.com
Machining

Machining

Rake angle of the cutting tool is defined as the angle of orientation of tool’s rake surface from the reference plane (πR) and measured on some other plane. Depending on the plane on which it is projected and measured, it may have various names. At the same time, rake angle may have positive, negative or even zero value based on the inclination of rake surface from reference plane. Each of

Cutting velocity and cutting speed in straight turning
Machining

Machining

Conventional machining operation utilizes a wedge shaped cutting tool having one or more sharp cutting edges to facilitate shearing. To achieve material removal, three relative motions between workpiece and cutting tool are indispensably necessary. These are also called process parameters. One of such three relative motions is cutting velocity, other two being feed motion and depth of cut. In few machining processes, the cutting velocity is imparted either by rotating

Differences between machining and grinding
Machining

Machining

Primary objective of any subtractive manufacturing process is to remove layer by layer material from a solid 3-D blank to achieve desired shape, size and finish. Achieving high dimensional accuracy, close tolerance and surface finish are usually not possible by conventional machining processes like turning, milling, shaping, planing, drilling, etc. Such processes are mainly applied for bulk removal (stock removal) of material with high material removal rate. In order to

Differences between jig and fixture
Machining

Machining

In conventional machining, the cutting tool compresses a layer of work material to shear it off in the form of chips. Both the cutting tool and the workpiece is rigidly mounted on the machine tool maintaining appropriate orientation. All relative motions are also offered by the machine tool to smoothly accomplish material removal. In mass production of a product in conventional machine tool, same work is required to perform repeatedly

Differences between turning and milling
Machining

Machining

Conventional machining is one type of manufacturing process in which excess material is removed from a pre-formed blank by shearing in the form of chips using a wedge shaped cutting tool in order to get desired shape, finish and tolerance. There exist several machining processes to efficiently machine a wide variety of materials in innumerable ways. Turning and milling are just two examples of such machining processes. Others being tapering,

Differences between additive and subtractive manufacturing
Machining

Machining

Economic production of near-neat shape products with close tolerance and high accuracy is a challenging task for manufacturing industries. Two different approaches have evolved over the years for efficiently and economically fabricate such products. In one approach material is added layer by layer to build a 3-D component, while in other approach material is removed layer by layer to obtain desired 3-D product. As the name suggests, in additive manufacturing

Differences between coolant and lubricant
Machining

Machining

During conventional machining or metal cutting, excess material is gradually removed from the workpiece in the form of chips using a wedge shaped cutting tool. Primarily due to continuous rubbing between moving chips and rake surface of cutting tool, intense heat is generated at the cutting zone. In continuous machining, this cutting heat leads to increase in temperature at the cutting zone. Excessive cutting temperature has several detrimental effects on

Differences between dry machining and wet machining
Machining

Machining

Machining is one secondary manufacturing process that is performed to impart desired shape, size and surface finish by removing unwanted material from a solid 3-D blank. In conventional machining operations, the cutting tool compresses a thin layer of workpiece material to gradually shear it off in the form of chips. The primary shear zone exists surrounding the concentrated shear plane along which work material undergoes shearing to become chip. Initially

Differences between flood cooling and MQL
Machining

Machining

In conventional machining operations, the cutting tool comes in physical contact with the workpiece to remove material in the form of chips. This chips flow over the rake surface of the tool before leaving the cutting zone. Presence of relative velocity under high contact pressure between the flowing chips and rake surface of the tool leads to excessive rubbing and heat generation. Excessive cutting heat or temperature has several detrimental

Difference between single point and multi point cutting tool
Machining

Machining

Cutting Tool or Cutter is a wedge shaped device that compresses the workpiece material during machining to gradually remove excess material by shearing in order to obtain desired shape, size and accuracy. Geometry, orientation and material are three important factors that influence performance of a cutting tool in accomplishing material removal. Every conventional machining operation employs a physical cutting tool. Although basic shape and feature of such cutting tool vary

Difference between surface roughness and surface finish
Machining

Machining

After processing the workpiece by any surface modification process (such as metal cutting, surface treatment, forming, etc.), quality of the final surface can be judged based on several aspects. All such aspects are integrated by the term Surface Integrity. It covers all primary, standard and extended data sets related to quality of a solid surface. Assessing quality of machined surface is important for judging machinability for a combination of work-tool

Difference between surface roughness and surface integrity
Machining

Machining

Primary objective of machining or metal cutting operation is to provide desired shape and quality to the workpiece by removing excess material with the help of a cutting tool. Assessing quality of a machined surface is important for judging machinability for a particular combination of work-tool material under a specific machining condition. In the context of manufacturing, three terms—surface roughness, surface finish and surface integrity are commonly used to characterize

Difference between up milling and down milling
Machining

Machining

Milling is one type of conventional machining process primarily for generating flat or stepped surfaces. In peripheral milling, cutting velocity is imparted by rotating the milling cutter about a fixed horizontal axis; whereas, the feed rate is imparted by moving the workpiece (basically worktable) against the rotating milling cutter. Since both cutting velocity and feed rate are vector quantities, so based on their mutual directions, peripheral milling can be classified