Machining Process

Abstract

All metal parts, after being casted or formed has to be shaped into its final dimensions so that it could meet the required functionality, durability and aesthetic characteristics of a product. This shaping process requires metal removal which involves various complex phenomenon and factors, governed by a set of mechanisms that has been experimentally and analytically discovered and can be controlled by considering various tool geometry, optimized cutting conditions and better tool-work material combination. Merchant’s force model of the machining process recognizes the influence of the shear plane in determining all controlling factors such as the cutting conditions and inputs for optimized force and power utilization, good surface finish and longer tool life. In this chapter, these factors and conditions that govern the basic mechanics of metal cutting including the various type of chips and their desirability issues, crater wear and flank wear (that determines the limit of usage of any cutting tool) has been explained in detail. Turning is a fundamental operation (carried out on lathe machines) in any machining research due to its involvement of a single point cutting tool and the ability to reduce the complex problem (representing complex phenomenon) into 2 dimensional simple problems. Other operations involve either a single point or multi point cutting tool and includes boring, milling, drilling, reaming, etc.