Machining Processes 1 MDP 114 First Year Mechanical
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Machining Processes 1 (MDP 114) First Year, Mechanical Engineering Dept. , Faculty of Engineering, Fayoum University Dr. Ahmed Salah Abou Taleb 1
Aims of the course This course is designed to provide students with a thorough understanding of the fundamentals of cutting tools for machining and materials removal. Turning, boring and related machining processes. Drilling and related hole making processes. Milling, broaching, sawing, shaping and planing, and abrasive machine processes. 2
Course Outlines Part One: Ø Introduction to Machining Processes. Ø Cutting Tool Materials and Its Characteristics. Ø Practical Machining Operations: Turning, Shaping, Drilling, Milling, Grinding. Ø Basic Elements of Machine Tools and Specifications. Ø Machining Time. Ø Mechanics of Metal Cutting ; Geometry ; Chip Formation; Wear ; Life; Temperature; Merchant Circle. Ø Economics in Cutting Process. 3
Course Outlines Part Two: Ø Introduction and Definitions of Metrology Ø Gauges. Ø Errors in Measurement. Ø Linear Measuring Instruments. Ø Angle Measuring Instruments. Ø Tests of Straightness and Flatness. Ø Surface Roughness. Ø Comparators. 4
Teaching and Learning Methods q Power Point Lectures. q. Assignments. q Quizzes.
Weighting of Assessment Final Exam 70 Mid Term Exam 20 Assignment 20 Oral 15 Total Marks 125
Introduction 7
Introduction 8
Introduction 9
Introduction Manufacturing Processes Casting Forming Fabrication Sand casting Shell mould Die casting Centrifugal Plaster mould Precision Permanent Rolling Drop forging Press forging Upset forging Extrusion Wire drawing Sheet metal Gas welding Electric arc W Ele. Resistance Thermal W Cold welding Brazing soldering Metal Removal Turning Drilling Milling Shaping Grinding Sawing broaching 10
Material Removal Processes A family of shaping operations, the common feature of which is removal of material from a starting workpart so the remaining part has the desired shape. • Categories: – Machining – material removal by a sharp cutting tool, e. g. , turning, milling, drilling – Abrasive processes – material removal by hard, abrasive particles, e. g. , grinding – Nontraditional processes - various energy forms other than sharp cutting tool to remove material
Material Removal Processes The family tree 12
Machining types • Turning • Drilling • Milling • Shaping • Planning • Broaching • Grinding 13