Manufacturing

Turning tool designation in ORS system and NRS system
Engineering

Engineering

Machining or metal cutting is one type of subtractive manufacturing process where excess material is gradually removed from the preformed blank to produce desired three dimensional feature or product. Conventional machining processes (like straight turning, taper turning, internal turning, threading, facing, drilling, boring, reaming, tapping, planing, shaping, slotting, milling, fly cutting, hobbing, grooving, parting, etc.) utilize a sharp wedge shaped cutting tool (cutter) to remove unwanted material. This cutter compresses

Difference between rough cut and finish cut in machining
Engineering

Engineering

Machining or metal cutting is one of the secondary manufacturing processes by which excess material is gradually removed from a preformed blank to obtain desired shape, size and finish. There exist larger number of processes to fulfil the basic requirement of machining. Such processes can be broadly classified as conventional machining processes (turning, threading, facing, drilling, boring, shaping, planing, milling, grooving, reaming, etc.), abrasive cutting processes (grinding, lapping, honing, polishing,

Cutting speed and feed rate in straight turning in lathe
Engineering

Engineering

Machining or metal cutting is one type of secondary manufacturing process by which excess material is gradually removed by shearing from pre-formed blank in the form of chips using a wedge shaped cutting tool to obtain desired shape, size and finish. It is one subtractive manufacturing process, which indicates layer by layer material is removed to get desired form. There exist a large number of such processes—each having different capability

Relation among cutting speed and cutting velocity in turning
Engineering

Engineering

Metal cutting or machining is one of the secondary manufacturing processes by which excess material is gradually removed by shearing from a pre-formed blank in the form of chips using a wedge shaped cutting tool in order to obtain intended form having better finish, high dimensional accuracy and close tolerance. It is one type of subtractive manufacturing process where layer by layer material is removed from a solid blank to

Surface profile of a highly finished surface
Engineering

Engineering

Primary aim of secondary manufacturing processes is to obtain products having better surface quality, high dimensional accuracy and close tolerance. Such processes include machining or metal cutting operations (like turning, milling, drilling, reaming, precision turning, grinding, lapping, honing, AJM, USM, EDM, LBM, IBM, etc.) and surface modification operations (like heat treatment, coloring, coating, etc.). Each of these processes has varying level of capabilities in terms of surface quality and precision.

Surface integrity (SI) data set by Field et al. (1972)
Engineering

Engineering

Functional performance of any solid surface relies on the physical conditions and chemical composition of the concerned surface and subsurface layers. Quality is defined as fit for intended purpose. Similarly, quality of a solid surface is one subjective matter and its assessment primarily depends on intended functionalities. Let us explain the same with examples. With respect to decorative artefact, appearance of the surface has importance rather than presence of micro-cracks

Difference between SMAW, GMAW and GTAW welding
Engineering

Engineering

Welding is one fast and reliable joining technique that has almost replaced other permanent joining processes. It can be defined as one joining process by which two or more materials can be assembled permanently with or without the applications of heat, pressure and filler. It can be overwhelmingly used for joining not only metals but also other types of materials including plastics and ceramics. To cater the need of joining

Differences between orthogonal rake and normal rake
Engineering

Engineering

Turning is one machining or metal cutting process (subtractive manufacturing) used to reduce diameter of a cylindrical workpiece by gradually removing excess material. It is performed on a versatile machine tool, called lathe, using a single point cutting tool. As the name suggests, a single point cutter contains only one main cutting edge that participates in material removal action during machining. Turning tool, formally known as single point turning tool

Shielded metal arc welding (SMAW) process
Engineering

Engineering

Welding is one of the joining processes by which two or more solid components can be joined permanently by coalescence formation with or without the application of heat, pressure and filler metal. There exist a large number of welding processes for efficient and productive joining of wide variety of materials in several ways. Based on the application of heat from external source during welding, such processes can be classified as

Typical rivet joining of pipelines
Engineering

Engineering

Rivet joining is one type of permanent joining process that can join two metallic components sufficiently strongly. It provides a durable, sound and reliable joint; especially the anti-loosening capability even under incessant vibration favors riveting over welding in many occasions including bridge constructions. Riveting is basically lap joining of two parts using rivets with the assistance of strap plates. Rivet is basically a small cylindrical rod usually made of soft

End mill is a multi-point cutting tool
Engineering

Engineering

Machining or metal cutting is one secondary manufacturing process where excess material is gradually removed from the workpiece in order to impart desired finish, dimension and tolerance. To cater the need of efficiently and economically machining a wide variety of materials in different ways, several relevant processes have emerged over the years. Broadly these processes can be grouped as conventional machining (macro and micro), abrasive finishing and non-traditional machining (NTM).

Conventional machining - rake angle and clearance angle
Engineering

Engineering

Machining or metal cutting is one subtractive manufacturing process that is used to gradually remove excess material from a pre-formed blank in order to achieve high dimensional accuracy and close tolerance. There are various types of machining operations to efficiently and productively accomplish material removal task on various work materials in varying level of precision. Such processes can be broadly classified as—conventional machining (like turning, facing, milling, drilling, boring, hobbing,

Conventional machining - rake angle and clearance angle
Engineering

Engineering

Conventional machining or metal cutting operation is performed to gradually remove excess layer of material from the workpiece to impart intended shape, dimension and finish. Material removal is realized with the help of a small device called cutter or cutting tool. During machining, the cutter as well as the workpiece is rigidly mounted on the machine tool with the help of various arrangements. Relative velocity between cutter and workpiece is

Classification of rake angles positive rake negative rake and zero rake
Engineering

Engineering

Machining is one subtractive manufacturing process by which excess material is removed from pre-formed blank in the form of chips in order to improve dimensional accuracy and tolerance. A wedge shaped cutting tool (or cutter) is employed for gradual shearing of layer by layer material. Geometry, orientation and material are three paramount factors that influence machining capability and product quality.  Cutter geometry embraces crucial features of the cutting edge(s) and

Turning operation in lathe
Engineering

Engineering

Machining or metal cutting is one subtractive manufacturing process that is predominantly used to remove unwanted material from workpiece to improve dimensional accuracy and tolerance. Over the ages multifarious machining processes have been evolved for efficient processing of a larger variety of materials in innumerable ways. Broadly such processes can be classified as conventional machining processes, abrasive finishing processes and non-traditional machining (NTM) processes. By definition, conventional machining is one

Typical grinding process - a finishing operation
Engineering

Engineering

Machining or metal cutting is one of the manufacturing processes by which excess material is gradually removed from a pre-formed blank to provide desired shape, size and finish. It is one subtractive manufacturing process that is primarily used to improve dimensional accuracy and tolerance level. To efficiently and economically process various materials in several ways, there exist various machining processes, each having different capability in terms of material removal rate

Typical face milling process - a machining operation
Engineering

Engineering

Fabricating complicate shaped products with good surface finish by casting is not always feasible and economical. Various secondary operations can be performed on the casted products to finally produce the desired object. Such operations include joining (such as welding), material removal or machining, heat treatment or property alteration, coloring and coating, etc. Material removal processes basically removes material from workpiece surface to provide intended dimension and tolerance. A large number

Differences between MIG welding and MAG welding
Engineering

Engineering

Welding is one of the joining processes that can efficiently and economically assemble two or more metallic or non-metallic parts permanently. With the extensive development throughout the years, a large number of such processes has evolved in order to cater the need to join a large variety of materials in innumerable ways. Gas metal arc welding (GMAW) is one such process where metallic materials are joined permanently by melting faying

Gas metal arc welding (GMAW) process
Engineering

Engineering

Welding is one of the popular joining techniques that can permanently join two or more materials together with or without the application of heat, pressure and filler material. Fusion welding is that group of welding processes where faying surfaces of parent component are fused by heating in order to form coalescence. Arc welding is most popular fusion welding process where heat is applied by means of electric arc constituted between

Tungsten inert gas (TIG) welding
Engineering

Engineering

Welding is one of the popular joining processes that has almost superseded other permanent joining processes including riveting. Intensive development of welding technique throughout last few decades makes it prominent choice for joining of metallic structures, plastics and even ceramics. By definition, welding is one of the joining processes that can permanently join two or more components by coalescence formation with or without the application of additional filler material, heat

Various fastening elements
Engineering

Engineering

Primary objective of manufacturing is to convert raw materials or scraps into desired consumer products by adding substantial value to it. Such conversion may not always possible in single step and usually requires multiple steps where each step incorporate certain functionalities into the product. There exist various manufacturing processes including age oil processes like casting, forming, joining, machining, and surface working and also newly developed processes like rapid prototyping and

Differences between temporary joining and permanent joining
Engineering

Engineering

Joining is a part and parcel of manufacturing as it facilitates easy and economic production of intricate shaped objects. By definition, joining is one of the manufacturing processes by which two or more solid components can be assembled together to obtain a single unit. As usual a large number of joining processes exists in order to assemble wide variety of materials in multifarious ways that are expected to serve different

Manual metal arc welding (MMAW) process
Engineering

Engineering

Welding, along with fastening, is extensively used for various industrial and household assembly purposes. Welding is one type of joining process by which two or more solid components can be joined permanently by coalescence formation with or without the application of filler metal, heat and pressure. With the development of welding technology, now-a-days it has mostly superseded other permanent joining techniques including riveting. Welding can be applied for efficiently and

Flux bound tungsten inert gas (FB-TIG) welding
Engineering

Engineering

Welding is one age old joining process that can efficiently and economically assemble two or more structural members permanently. There exist a large variety of welding processes that can join structures of various materials in multifarious ways. Gas Tungsten Arc Welding (GTAW), popularly known as Tungsten Inert Gas (TIG) welding, is one of the fusion welding processes where metals can be joined by coalescence or weld bead formation due to

Activated tungsten inert gas (A-TIG) welding
Engineering

Engineering

Tungsten Inert Gas (TIG) welding is one popular arc based welding process where electric arc is constituted between a non-consumable tungsten electrode and the workpiece. It is one reliable and economic process to efficiently and permanently join metallic parts with or without the usage of filler metal. Apart from its capability of producing sound joints, splendid weld bead appearance makes this process overwhelmingly acceptable in various applications ranging from structural

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