Machining is a metal-removing process that removes a material & decreases the material’s mass; hence, this is a subtractive process.
The conventional machining process is also known as a traditional machining process. It is the fundamental method of the metal-removing process, which involves the removal of material and the reduction of metal mass.
Because of the abrasive reinforcement and inhomogeneous structure, traditional machining procedures are known to produce low-quality products. As a result, laser machining has some advantages over traditional machining technologies.
Well, in this reading, we’ll explore what conventional machining is, its applications, parts, diagrams, types, and how it works. We’ll also look at its advantages and disadvantages.
Let’s begin!
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What is Conventional Machining?
A conventional machining process involves traditionally performing the machining without the use of sophisticated methods. As a result, this machining method is also known as traditional machining.
This machining technique uses sharp-point cutting tools, such as the taper tool in the lathe machine.
Because the cutting tool’s material is tougher than the workpieces, and because the cutting tool is in direct contact with the workpiece, there is increased tool wear. We employ the cutting tool against a rotary or fixed workpiece for material removal.
Because of the abrasive reinforcement and inhomogeneous structure, traditional machining procedures are known to produce low-quality products. As a result, laser machining has several advantages over traditional machining technologies.
Examples of conventional machining include lathe machines, milling machines, vertical drilling machines, grinding machines, etc.
Molding components with contouring channels are difficult to produce using traditional machining. We construct the channels using milling and drilling in a configuration that closely resembles the conformal system.
This ensures rapid and smooth cooling, as well as the benefits of a short cycle time and excellent plastic part quality.
But because the drilled channels are straight and can’t curve the molding surface evenly, there are fewer channels for the same mold volume. This is due to the way shapes function, which is why a decrease in cooling performance is expected.
The created channels represent a first step toward achieving a “pure” cooling system, which is only conceivable with AM technologies in this shape.
Applications
Because there are different types of conventional machining processes with various operations, their applications vary. The most commonly used include,
- Knurling, turning, facing, screw cutting, and taper operations on lathe machine
- Surface smoothing on milling
- Drilling holes in a workpiece using a drill machine
- The shaper machine features surfacing, internal, and external keyways.
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Machine Tools’ Basic Functions
By machining work with the use of cutting tools, machine tools produce geometrical surfaces such as flat, cylindrical, or any contour on prepared blanks. A machine tool’s physical functions in machining are as follows:
- transfer motions to the tool and the blank by firmly gripping the blank and the tool
- control of the machining parameters, such as speed, feed, and depth of cut;
- give power to the tool-work pair for machining action;
Components of A Conventional Machining Process
Traditional machining processes are different in their constructional features. However, the following are the basic elements of conventional machines:
- Work holding device
- Tool-holding device
- Work motion mechanism
- Tool motion mechanism
- Support structure
Work Holding Device
During machining, welding, and assembly activities, work-holding devices locate, support, and secure workpieces. Chucks, collets, vises, jigs, and fixtures are all common workholding devices.
These typical devices provide the majority of work-holding in a wide range of applications. It is a critical component of a variety of manufacturing processes.
Operators who understand how to operate the various workholding devices are necessary for efficient, safe, and high-quality part production. When used correctly, it increases production speed while also improving part tolerance and finish.
Tool Holding Device
A tool holder, a machining component, holds a machine in place. It aims to keep the tool as precise and firmly in position as possible because even a small increase in runout might destroy your job or break your cutting tool.
Different types of holders exhibit variations in their runout and balance. There’s also a difference in how long they last and how durable they are.
Work Motion Mechanism
This system within the machine provides power to the mechanism that regulates the workpiece’s movement. This often involves electric rotary motion, which can be applied to any type of motion.
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Tool Motion Mechanism
This is a mechanism that controls the tools during the operation.
Support Structure
The part on the machine bears all the load of the traditional machine tool.
Diagram
Types of Traditional Machining and Their Operations
Below are the various types of conventional machining processes and their operations
Lathe
A lathe spins the workpiece as cutting tools move across it during the turning process. To make cuts with exact depth and width, the cutting tools move along two axes of motion. Traditional manual lathes and automated computer numerical controlled (CNC) lathes are the two types of lathes available.
Grinder
Grinding is a technique for removing small amounts of material from flat and cylindrical surfaces. Surface grinders feed work from a table into a grinding wheel in a reciprocating motion.
The cutting depth of the wheel is normally between 0.00025 and 0.001 inches. Cylindrical grinders rotate the workpiece while applying the periphery of a revolving abrasive wheel to it.
Centerless grinding is a technique for mass-producing small parts in which the ground surface has no link to any other surface other than itself.
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Milling Machine
In contrast to turning processes, where the tool does not spin, milling removes material using revolving cutters. Traditional milling machines position the workpieces on moving tables.
The cutting tools are stationary on these machines, while the table moves the material to make the desired cuts. Tables and cutting tools are both moveable components on other milling machines.
Planer
Planning is typically used to mill large flat surfaces, especially those that will be scraped, such as machine tool paths. Planning also takes into account the economics of grouping small pieces in a fixture.
Drill Press
Drilling is a crucial machining technique that creates cylindrical holes in solid materials, typically to facilitate assembly. People frequently use drill presses, but they can also use lathes.
Drilling is a preparatory step in most manufacturing operations for producing finished holes, which are then tapped, reamed, bored, etc. to generate threaded holes or bring hole dimensions within acceptable tolerances.
Due to the bit’s flexibility and tendency to seek the route of least resistance, drill bits will frequently cut holes that are larger than their nominal size and holes that are not always straight or round.
Therefore, it is common practice to specify drilling undersize and then use a machining process to bring the hole to its final size.
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How Does Conventional Machining Work?
Conventional machining works by removing materials from workpieces using a cutting tool, which helps in shaping them into the desired form. Metals, plastics, and other solid materials find widespread use in this process.
The machine securely mounts the material to ensure stable and precise operation. Depending on the material and desired outcome, high-speed steel or carbide often serve as the cutting tools.
The material removal may occur through different mechanical actions like turning, milling, or drilling. Their cutting tool moves relative to the stationary or rotating workpiece.
This interaction generates heat and friction, which is why adequate cooling or lubrication is required. This helps to prevent overheating and ensure a smooth finish.
When combined with a CNC system, conventional machining can create complex geometries with tight tolerances.
Advantages and Disadvantages of Conventional Machining
Advantages
Below are the benefits of a traditional machining process in its various applications.
- Different materials can be machined
- Equipment can be easily setup
- Less capital cost
- The basic method of machining
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Disadvantages
Despite the advantages of the traditional machining process, some limitations still occur. Below are the disadvantages of the conventional machining processes in their various applications.
- Less surface finish is produced
- Complex shapes cannot be machined
- Tool wear frequently occurs.
- Low dimensional accuracy
- Noisy operations result in sound pollution
- Lubrication is necessary.
Conclusion
A traditional machining process is a conventional process that does not make use of any sophisticated methods. It is a metal-removing process. This process involves the removal of a material and a decrease in its mass, making it a subtractive procedure.
Conventional machining refers to traditional material removal processes that use mechanical cutting tools to shape workpieces. Techniques such as turning, milling, drilling, shaping, and grinding fall under this category. These methods are widely used in workshops and manufacturing industries due to their simplicity, cost-effectiveness, and proven reliability.
While non-conventional machining methods are growing in popularity for complex and hard-to-machine materials, conventional machining remains a fundamental part of modern production environments for a wide range of general applications.
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Frequently Asked Questions (FAQs)
What is conventional machining?
It is a category of material removal processes that involves direct contact between a cutting tool and the workpiece, typically using tools like lathes, mills, and drills.
What are examples of conventional machining processes?
- Turning (lathe)
- Milling
- Drilling
- Grinding
- Shaping
- Planning
What are the advantages of conventional machining?
- Simple to operate
- Cost-effective equipment
- Ideal for producing simple to moderately complex parts
- Readily available tools and machines
What are the disadvantages?
- Not suitable for very hard materials
- Limited precision compared to CNC and non-conventional methods
- Tool wear is common
- Slower for complex or high-volume production
How does conventional machining differ from non-conventional machining?
Conventional machining uses mechanical cutting and physical contact, whereas non-conventional methods (like EDM, laser cutting, waterjet) use electrical, thermal, or chemical energy without direct tool contact.
Is conventional machining still used today?
Yes, it is still widely used in small workshops, for prototyping, and for applications where high precision or automation is not required.
Can conventional machines be automated?
Yes, with the use of attachments or CNC retrofits, conventional machines can be partially automated, although not as efficiently as full CNC machines.