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    Importance of Machining 

    One of the primary concepts in manufacturing 
    Manufacturing plays a very major role in any country's GDP
    Majority of the pillars of historical monuments such as temples are developed based on machined components

    What is Manufacturing?
    In simple terms,  manufacturing is the conversion of raw material into a finished product using some energy. Manufacturing is one of the value addition process by which raw materials of low utility and value due to inadequate material properties and poor, or irregular size shape finish are converted into high utility and valued products with definite dimensions forms and finish imparting some functional ability.
    Approaches to Manufacturing 

    Top Down (Subtractive Manufacturing) 
    Bottom Up (Additive Manufacturing) 

    Machining 
    Machining is the process of removal of excess material in the form of chips or otherwise to give desired shape, size, surface roughness and the tolerance on the workpiece obtained from primary manufacturing process.
    Importance of Cutting fluids in Manufacturing
    1) Primary function of cutting fluid is lubrication to reduce friction between contact surfaces.2) Cooling the cutting zones.3) Flushing chips away from the cutting zone.4) Corrosion protection of the machined surface.5) Longer Tool Life.6) Reduce Thermal Deformation of Workpiece.7) Better Surface Finish (in some applications).8) Enabling part handling by cooling the hot surface.9) Ease of Chip handling.
    Classification of Manufacturing Processes
    Type I 
    1)Casting
    2)Forging
    3)Moulding
    4)Forming
     
    Type II
     

    1)Machining
    2)Finishing

     
    Type III
     

    1) Welding
    2) Brazing
    3) Riveting
     

     
    Type IV
     

    1)Painting
    2)Electroplating
    3)3D printing
     
    Multi-Point Cutting Tool Processes
    The following are the overview of various multi-point Cutting tool processes: 



    Drilling Process


    Reaming Process


    Tapping Process


    Milling Process


    Broaching Process


    Grinding Process


    Honing Process

    Finishing Or Polishing Process

    Machining of Brittle Materials
    I. The chip separation ts effected by brittle fracture requiring lesser energy of chip formation
    II. Shorter chips causing lesser frictional force and heating at the rake surface
    III. No Built-up edge (BUE)formation
     
    Machining of Ductile Materials
     
    Smooth and continuous cutting (Continuous chip formation) in ductile materials produce better surface finish but BUE formation may worsen the surface finish. 
     
    Shear Zones
     
    There are three (3) main shear zones in metal cutting namely
     

    I. Primary shear zone: Present between work piece and chip region
    II. Secondary shear zone: Present between chip and tool region
    III. Tertiary shear zone: Present between tool and work piece region
     
    Types of Chips 
     


    Continuous Chips 

    Continuous Chips with BUE 


    Serrated or Segmented Chips



    Discontinuous Chips