MACHINING BY CHIP REMOVAL
Machining by chip removal is a manufacturing technique that involves the removal of material from a raw workpiece to obtain the desired shape. This process is performed using cutting tools that can be mounted on machine tools such as lathes, milling machines, drills, and grinders. The precision and surface quality obtained through these processes make them essential in many industries, including automotive, aerospace, and manufacturing.
Main Machining Techniques
The main chip removal machining techniques include:
- Turning
- Milling
- Drilling
- Grinding
Turning
Turning is a machining process in which the workpiece is rotated while a cutting tool is advanced along the surface of the piece. This process is ideal for producing cylindrical and conical parts.
| Parameter | Typical Value |
| Cutting Speed | 100-400 m/min |
| Feed Rate | 0.1-0.5 mm/rev |
| Cutting Depth | 0.5-5 mm |
Milling
Milling uses a rotating tool with multiple cutting edges to remove material from a stationary workpiece. This process is used to produce flat surfaces, grooves, and complex profiles.
| Parameter | Typical Value |
| Cutting Speed | 50-300 m/min |
| Feed Rate | 0.02-0.1 mm/tooth |
| Cutting Depth | 1-10 mm |
Drilling
Drilling is a machining process used to create cylindrical holes in material using a cutting tool called a drill.
| Parameter | Typical Value |
| Cutting Speed | 20-150 m/min |
| Feed Rate | 0.05-0.3 mm/rev |
| Cutting Depth | Up to 5D (diameters) |
Grinding
Grinding is a finishing process used to achieve a very smooth surface and precise dimensions through abrasion with a grinding wheel.
| Parameter | Typical Value |
| Cutting Speed | 20-50 m/s |
| Feed Rate | 0.005-0.05 mm/rev |
| Cutting Depth | 0.01-0.1 mm |
Graph: Cutting Speed vs Material
The graph above shows the optimal cutting speed for different commonly machined materials, such as steel, aluminum, and cast iron.
Images of Tools and Machines
The following image shows a CNC milling machine in action:
Applications of Chip Removal Machining
Chip removal machining finds application in many sectors, including:
- Automotive Industry: Production of engine components, shafts, gears, and structures.
- Aerospace Industry: Machining of structural parts, turbines, and precision components.
- General Manufacturing: Production of tools, molds, machine parts, and equipment.
Conclusion
Chip removal machining represents an essential technology for companies looking to produce high-precision and quality components. Adopting advanced machine tools and innovative machining techniques can significantly improve production efficiency, reduce cycle times, and lower operational costs.