# Material Removal Processes for Round Shapes ATILIM VERS TES by nikeborome

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```									IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

MATERIAL REMOVAL PROCESSES
AND MACHINES

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

MACHINING PROCESSES
FOR
PROCESSING ROUND SHAPES

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                            Dr. Zühal ERDEN

TURNING
The workpiece is rotating, while it is being machined.

Turning  to produce straight, conical, curved or grooved
workpieces

Facing  to produce a flat surface at the end of the workpiece

Boring  to enlarge a hole or to produce internal grooves

Drilling  to produce a hole

Parting  to cut a piece from the end of a part

Knurling  to produce a regularly shaped roughness on cylindrical
surfaces
Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN

Material Removal Rate (MRR)

Atılım University / Dept. of Industrial Engineering
Material Removal Rate (MRR)

Volume of material removed per unit time (mm3/min)

A = f.d

A: cross-sectional of the ring-shaped layer
f: feed (the distance that the tool travels per revolution)
d: depth of cut
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN

Average circumference of the ring = .Davg

Davg = (D0 + Df) / 2

MRR per revolution = (.Davg).f.d

For N revolutions per unit time (per minute);

MRR = (.Davg).f.d.N

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN

Cutting time, t;

t = l / f.N
l: length of the w/p

Feed rate = f.N = (mm/rev).(rev/min)= (mm/min)

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Lathes and Lathe Operations

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Turret Lathes

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Computer-Controlled Lathes

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                                      Dr. Zühal ERDEN

BORING AND BORING MACHINES

Producing circular internal profiles in hollow workpieces
or on a hole made by drilling or another process.

Boring Mills for large workpieces

Boring Mills  Turning, facing, grooving, chamfering

Boring Mills

Vertical                                       Horizontal

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN

DRILLING AND DRILLS

Drilling is a holemaking operation. Holes are used either
for assembly with fasteners or to provide access inside
a part.

Drills

 High length-to diameter ratio, produces deep holes

 Flexible

 Chip disposal

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                               Dr. Zühal ERDEN

MRR in Drilling

Volume of material removed by the drill per unit time.

For a drill with diameter D, the cross-sectional area of
the drilled hole is;

D2/4

The velocity of the drill perpendicular to the workpiece

V = f.N

where, N : rotational speed
f= feed (the distance the drill penetrates per revolution)

N = V / D
MRR =    (D2/4)(f)(N) in mm3/min

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                            Dr. Zühal ERDEN

Drilling Machines

Used for drilling holes, tapping, reaming and other
small diameter boring operations.

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

REAMING AND REAMERS

Reaming is an operation used to make an existing hole
dimensionally more accurate.

Centering
Drilling
Boring
Reaming

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                        Dr. Zühal ERDEN

Atılım University / Dept. of Industrial Engineering
IE 204 Manufacturing Processes                         Dr. Zühal ERDEN

TAPPING AND TAPS

Production of internal threads. Tapping can be done by
hand or in drilling machines, lathes or automatic screw
machines.

Atılım University / Dept. of Industrial Engineering

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