Material Removal

1
Forging new generations of engineers
2
Material Removal
3
MATERIAL REMOVALMETHODS

• SAWING
• DRILLING
• MILLING
• ABRADING
• TURNING
• SHEARING
• THERMAL
• NON-TRADITIONAL

4

• CIRCULAR SAWING

RIPPING
CROSS CUTTING
TABLE SAW
5
CIRCULAR SAWING
RADIAL ARM CIRCULAR SAW SET-UP TO CROSSCUT
6
CIRCULAR CUTOFF SAW
CIRCULAR BLADE
7
BAND SAWING
HORIZONTAL
VERTICAL
BOTH SAWS USE A CONTINUOUS BAND BLADE THAT IS
MOUNTED AND MOVED ON TWO WHEELS
8
PORTABLE BAND SAW
THIS 3-WHEEL BAND SAW IS SMALL BUT HAS A LARGE
CUTTING RADIUS ITS NARROW BLADE CAN CUT VERY
SHARP CURVES IT IS ALSO VERY LOW IN WEIGHT SO
ITS PORTABLE
9
BANDSAW CUTS
RESAWING
CURVE CUTS
STRAIGHT CUTS
COMPOUND CUTS
10
RECIPROCATING JIG SAW
VERY THIN BLADE CUTS VERY SHARP CURVES
11
HOLE SAW KIT
12
HOLE SAWINGWITH A DRILL PRESS
HOLE SAW
13
HOLE SAWING SAMPLE
14
DRILLS AND DRILLING
DRILL INDEX CONTAINING DECIMAL, NUMBER LETTER
DRILLS
15
TYPES OF DRILLS
TAPERED SHANK
STRAIGHT SHANK
16
COUNTERSINKS
60 DEGREE CUTTING ANGLE OF CUTTING EDGES
17
COUNTERSINK COUNTERBORE
18
PILOTED COUNTER BORE SET
19
DRILL REAMER
A REAMER IS USED TO FINISH AN EXISTING HOLE
GIVING IT A SMOOTH SURFACE FINISH AND A VERY
ACCURATE DIAMETER
A DRILL CUTS A HOLE THAT IS ONLY CLOSE TO THE
SIZE NEEDED
20
TYPES OF REAMERS
EXPANSION PILOTED SPIRAL STRAIGHT
TAPERED
21
DECIMAL LETTER REAMERS
22
PILOT HOLE DRILLING
23
COUNTERSINKING
24
COUNTERBORING
25
DRILLING SAMPLES
PILOT HOLE
COUNTERSINK
COUNTERBORE
26
REAMING
REAMING A HOLE PROVIDES A SMOOTH SURFACE FINISH
AND A VERY ACCURATE SIZE DIAMETER. IT FINISHES
A DRILLED HOLE
27
FLAT MILLING
TYPES OF HORIZONTAL MILLING
EDGE MILLING
BEVELING
SLITTING
28
GROOVE MILLING
29
VERTICAL MILLING CUTS
FLAT MILLING
FACE MILLING
EDGE MILLING
GROOVE MILLING
30
VERTICAL MILL CUTS
SLOT MILLING
CORNER ROUNDING
DRILLING
T-SLOT MILLING
31
VERTICAL MILL CUTS
THREADING
REAMING
BORING
THREAD WITH BOLT
32
CNC VERTICAL MILLING
33
MATERIAL REMOVAL BROACHING
BROACHING KIT
34
BROACH DESIGN FUNCTION
SIDE AND EDGE VIEW OF BROACH
BROACH DESIGN

CUTTING TEETH
35
ABRASIVE MATERIAL REMOVAL
DISC SANDING
36
ABRASIVE MATERIAL REMOVAL
GRINDING
37
ABRASIVE MATERIAL REMOVAL
SURFACE GRINDING
38
ABRASIVE MATERIAL POLISHING
BUFFING
39
ABRASIVE CUTOFF
A VERY THIN BUT LARGE DIAMETER ABRASIVE DISC IS
ROTATED AT A HIGH SPEED. THE SURFACE SPEED OF
THE OUTER EDGE OF THE DISC IS VERY HIGH. WHEN
THESE ABRASIVES ARE FORCED DOWN ON THE WORK
INTENSE HEAT IS CREATED AT THE POINT OF CONTACT.
THIS HEAT MELTS THE METAL IN ITS PATH AND THE CUT
IS MADE.
40
LATHE TURNING
FACING
PARALLEL TURNING
SHOULDERING
DRILLING
41
LATHE TURNING
BORING
THREADING
TAPERING
CENTER DRILLING
42
SQUARING SHEAR USED FOR CUTTING SHEET METAL
43
SHEARING MATERIALS
NOTCHING
PUNCHING HOLES
44
THERMAL MATERIAL REMOVAL
OXY-ACETYLENE CUTTING TOURCH
PLASMA CUTTER
45
NON - TRADITIONAL MATERIAL REMOVAL
EDM ELECTROCHEMICAL
46
LASER BEAM MATERIAL REMOVAL
LASER BEAM
LASER MILLING