High removal rate (HRR) machining involves the use of extremely rigid, high-power, high-precision machines, such as roll turning lathes, to achieve material removal rates far beyond the capacity of conventional machine tools. This article reviews the machine requirements and cutting parameters of HRR machining. Machine components such as the lathe bed, tailstock, headstock, carriage, and tooling are detailed. The article also discusses the applications of HRR machining.

The machinability of carbon and alloy steels is affected by many factors, such as the composition, microstructure, and strength level of the steel; the feeds, speeds, and depth of cut; and the choice of cutting fluid and cutting tool material. This article describes the influence of the various attributes of carbon and alloy steels on machining characteristics. It lists the relative machinability ratings for some plain carbon steels, standard resulfurized steels, and several alloy steels. The addition of lead to carbon steels is one of the means of increasing the machinability of the steel and improving the surface finish of machined parts. Low carbon content of carburizing steels may be beneficial to tool life and production rate. The sulfur content of through-hardening alloy steels can significantly affect machining behavior. Cold drawing generally improves the machinability of steels containing less than about 0.2% carbon.

This article begins with a discussion on machinability ratings of copper and copper alloys and then describes the factors influencing the machinability ratings. It explains the effect of alloying elements, cold working, and cutting fluid on the machinability of copper and copper alloys. In addition, the article provides a comprehensive discussion on various machining techniques that are employed for machining of copper and copper alloys: turning, planing, drilling, reaming, tapping and threading, multiple operation machining, milling, slitting and circular sawing, power band sawing and power hacksawing, grinding, and honing.

This article discusses the factors to be considered in selecting and evaluating machining tests for the purpose of evaluating cutting tool performance and workpiece machinability. It provides a brief description of cutting tool materials, such as high-speed steels, uncoated and coated carbides, cermets, ceramics, cubic boron nitride, and polycrystalline diamond. The article considers the matrices that represent the range of tests performed on candidate cutting tool materials: the workpiece matrix, the property matrix, and the operation matrix. Various machine tests used to evaluate cutting tools, including the impact test, turning test, and facing test, are described. The article lists the factors to be taken into consideration in measuring the machinability of a material. The article presents general recommendations for proper chip groove selection on carbide tools and concludes with information on machining economics.

Machining is a term that covers a large collection of manufacturing processes designed to remove unwanted material, usually in the form of chips, from a workpiece. This article discusses the basic classes of machining operations, including conventional, abrasive, and nontraditional, and outlines the type of costs incurred by the process. It describes the types of machining equipment, including general-purpose machine tools, production machining systems, and computer numerically controlled machining systems. The article lists the common classes of metallic work materials, in order of decreasing machinability. It also shows the range of dimensional and surface finish tolerances in graphical form that can be achieved using various machining processes under general machining conditions.