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Process

Machining processes are divided into those that involve single point cutting and those that use multi-point cutting. This term relates to the number of cutting edges removing material at any given moment. The best-known single point cutting process is turning. Multi-point processes include milling and grinding. Drilling is technically multi-point but only involves the simultaneous use of two cutting edges.

Milling

This entails using a rotating cylindrical cutter with multiple edges to produce flat surfaces. Milling machines are defined by the orientation of the cutter axis: horizontal or vertical. Advanced milling machines have additional motion axes that enable machining of contoured surfaces.

Drilling

This process produces holes. Drilling machines usually have a vertical axis with the workpiece being moved underneath, although horizontal versions exist. When the depth-to- diameter ratio of the hole being drilled exceeds 10:1 the process is considered deep hole drilling, sometimes also called gun drilling, and requires specialized tools and techniques. Milling machines can usually perform drilling as well as milling.

Turning

This probably gets its name from the rotation of the workpiece against a fixed tool. Turning is performed on lathes, of which there are many configurations. A subset of turning is “hard turning”. This refers to single point turning of very hard parts that are more commonly machined by grinding.

Grinding

Grinding is applied to shafts, cylindrical surfaces, cylindrical bores and flat surfaces. Grinding of shafts and other cylindrical surfaces is performed on an OD (outside diameter) grinder. Internal cylindrical surfaces are ground on an ID (internal diameter) grinder. Surface grinders are used for flat surfaces.

A limitation of grinding in volume manufacturing is that machines need each workpiece to be loaded individually, which slows down the process. For OD grinding this is addressed by centerless grinding. A centerless grinder consists of two opposed grinding wheels with a rail or guide between them. Cylindrical workpieces are pushed along this guide from one side, emerging on the other. The major limitation of this is that only a single diameter can be produced.

Honing

Honing is another abrasive material removal process and is used to bring cylinder bores to size and shape while imparting specific surface finish characteristics. Unlike grinding, honing uses reciprocating motion of abrasive pads coupled with rotation to achieve this result. Honing is used to finish the bores of engine blocks and hydraulic system components. By correcting defects like waviness, barrel form and taper it enables the tighter piston and ring tolerances that improve.

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