Machining

2nd mid term exam syllabus

plastic processing
Joining and
machining up to lathe (machine,
operation and tool)
• Machining: A subtractive
process used to get desired What is it?
shape, size, and finish by
removing surplus material in
the form of chips by a cutting
tool and by providing suitable
relative motion between the
workpiece and cutting tool
• Cutting tool: removes excess
material through direct
mechanical contact
• Machine tool: provides
necessary relative motion
between the work-piece and
tool
 Basics of shape generation by machining
• Two relative motions (between work and tool)
generally needed to produce surfaces
– Cutting speed: line generated by it is called
generatrix: Primary cutting motion
– Feed speed: line generated by it is called
directrix: Secondary cutting motion
 Relative motions needed for
various types surface generation
Surface Machini Generatrix Directrix
Obtained ng (cutting) (feed)
Process
Planar Shapin Straight Straight
Surface g, Line Line
Planing
Cylindrica Turning Circular Straight
l Line
Planar Milling Circular Straight
Surface Line
Surface of Contour Plain Circular
Revolutio Turning Curve
n ,Boring
 TYPES OF MACHINING PROCESSES
BASED ON ANGLE BETWEEN CUTTING
EDGE and CUTTING VELOCITY
Oblique Machining Orthogonal Machining
¾ Cutting edge of the tool ¾ Cutting edge of the tool is
is inclined with normal perpendicular to the
to the cutting velocity. direction of cutting velocity
¾ Cutting Forces Act ¾ Cutting Forces Act Along x
along All Three and z Directions Only i.e.
Directions i.e. x, y, and No Cutting Force along y
z Axes. Direction
¾ Examples: ¾ Examples:
Turning, Sawing,
Milling, Broaching,
Drilling, Parting-Off of Tube Wall
Shaping
 MI-102: Manufacturing Techniques I. I. T.
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ACCORDING to TYPE of CUTTING TOOL
Machining Processes

Using SINGLE-Point Using MULTI-Point Using ABRASIVES

Cutting Tools Cutting Tools as Cutting Tools

¾ Turning ¾ Milling ¾ Grinding

™ Step Turning ¾ Drilling ¾ Honing
™ Taper Turning ¾ Reaming ¾ Lapping
™ Form Turning ¾ Knurling ¾ Super-Finishing
™ Contour Turing ¾ Tapping ¾ Polishing
¾ Facing ¾ Hobbing ¾ Buffing
¾ Necking ¾ Broaching
¾ Parting-Off
¾ Sawing
¾ Boring
™ Counter-
Boring
™ Counter-
Sinking
¾ Shaping
¾ Planing
 LATHE MACHINE and its OPERATIONS
¾ Lathes are Machine Tools Designed Primarily to Do
Turning, Facing, and Boring.
¾ Because Lathes also can Do Facing, Drilling, and
Reaming, their Versatility Permits Several Operations

DESIGN and TERMINOLOGY of the ENGINE LATHE

The Essential Components of an Engine Lathe are
1. Bed
2. Headstock Assembly 5. Feed Rod
3. Tailstock Assembly 6. Leadscrew
4. Carriage Assembly 7. Quick Change Gearbox

MI-102: Manufacturing Techniques I. I. T.

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 Tailstock

Bed
Schematic Diagram of an Engine Lathe
MI-102: Manufacturing Techniques I. I. T.
ROORKEE
 Carriage
assembly
¾ Carriage
assembly
provides the
means for
mounting and
moving cutting
tools.
¾ Carriage
assembly
consists of
carriage, cross
slide,
compound rest,
tool post

MI-102: Manufacturing Techniques I. I. T.

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 Feed rod
¾ provides
the
powered
movemen
t of the
carriage
and cross
slide for
automatic
movement
of tool
used in
turning Leadscrew
operation ¾ for cutting threads, a leadscrew is
used to provide automatic
movement to carriage.
SIZE DESIGNATION of LATHES
¾ Size of a Lathe is Designated by Two Dimensions:
1. Swing diameter: shows maximum diameter of work-
piece that can be rotated on a lathe.

2. Maximum Distance Between Centers: Indicates the

Maximum Length of Workpiece that can be Mounted
Between Centers.

Example: A 14 x
48 Lathe
designates that
the swing is 14
in. and the
maximum
distance
between centers
is 48 in.
• Engine lathe,
• Speed lathe, Type of
• Tool room lathe,
• Turret lathe,
lathes
• Automatic lathe,
• Numerical control lathe
 ENGINE LATHE
• Most frequently used in
manufacturing
• They are heavy duty
machine tools with all the
components have power
drive for all tool
movements except on
compound rest.
• Most engine lathes are
equipped with chip pans
and a built-in coolant
circulating system.
 SPEED LATHE
¾ Speed lathes usually
have only a
headstock, a
tailstock, and a
simple tool post
¾ Usually three or four
speeds
¾ Mainly used for
wood turning,
polishing, or metal
spinning
¾ Spindle speeds up to
4000 rpm.
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 Tool room lathe
• Greater accuracy and
usually a wider range
of speeds and feeds
than engine lathes.
• Designed to have
greater versatility to
meet the requirements
of tool and die work
• Generally used for
machining smaller
parts
 Turret lathe
• Hexagon Turret Replaces
the Tailstock
• Turret used for mounting
tools and feed into the work
piece
• Turret Lathes Use the 11 RAM TYPE
Station Tooling and so as
to increase production
rate by reducing tool
changing time .
• SIX Tools can be Mounted
on the Hexagon Turret
• Turret can be Rotated
about the Vertical Axis to
Bring Each Tool into the
Operating Position
Ram and saddle SADDLE
TYPE
type turret lathe
• Primary difference is
in mounting and size
of two types.
• Ram type is light,
less rigidity and so
for small jobs using RAM TYPE
fine cuts
• Saddle type heavy,
more rigid, large
jobs and heavy cuts
Turning is the process of Machining external
Operation of
cylindrical and conical surfaces. lathe
– Straight turning: for producing cylindrical shapes
– Taper turning: for producing conical shapes
– Facing: making edges square and clear
– Chamfering: slightly tapering and rounding off of
edges
– Threading: for producing threads
– Drilling: for creating /producing hole
– Boring: for enlarging hope and correcting shape
– Parting off or necking: separating or making square
groove
– Knurling: making impression for firm gripping
– Reaming: finishing purpose
 Straight/cylindrical turning

Orthogonal turning Oblique turning

TAPER TURNING

¾ Cutting tool is fed at an angle to the axis

of rotation producing an
external/internal conical surface.
¾ Tapers generally specified in degrees of
included angle between the sides (or rate
of change in diameter along the length
mm/mm)

¾ FOUR Methods for Taper turning:

¾ Swiveling the Compound Rest: Only for
Short and steep Tapers
¾ Taper turning attachment: for fine taper-ness
less than 0.5mm/mm
¾ Setting over tailstock: low taper in long jobs
¾ NC lathe with programmed both movements of
movement of tool
MI-102: Manufacturing Techniques I. I. T.
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Swiveling the compound rest
• Tool is set
at half of
taper angle
w.r.t. lathe
axis and
moved with
compound
rest only
Taper turning
attachment
• Cross
slide is
made free
and tool
is moved
with help
of
attachme
nt at an
angle
Off setting the tail stock

Tool is moved with help

of carriage parallel to the
lathe axis
 Contour turning

¾ The tool follows a contour

creating a contoured form on
the turned part instead of
parallel to the axis. Cross slide
is made free to follow the path
of contour.

FORM TURNING

¾ Cutting edge of Tool has a

Specific Form or Shape and is fed
radially inward towards the axis of
rotating work piece.
FACING

¾ Cutting tool is fed radially inwards

(at 90° w.r.t. the axis of rotation) into
the rotating work piece.

¾ End facing: facing by tool moving

radially outward from the center

¾ Shoulder facing: facing the stepped

cylindrical work piece
 Chamfering
¾ The tool is fed radially inward
used to cut an angle on the
corner of the cylinder,
forming a chamfer to avoid
sharp edges.

Parting off & necking

¾ Tool is fed perpendicular to

the rotational axis
¾ Necking is a making partial
cutoff

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 DRILLING
¾ The tool (Drill) mounted on the
tailstock of the engine lathes
is fed by hand against a
rotating work piece along the
axis of lathe.

BORING

¾ Tool mounted to tailstock is

fed parallel to the lathe axis
after giving suitable depth of
cut

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 REAMING
¾ It is semi-finishing
operation that enlarges
an existing hole. Tool is
rotated and fed along
rotational axis.
knurling
¾ Roughening the surface of work
piece for better gripping.
¾ No machining operation only cold-
forming takes place
¾ Process involves pressing of
two hardened rolls against the
rotating work piece with sufficient
force to form impression (the knurl)
like raised diamond pattern.
 Work holding
• Face plate: for holding irregular
devices
shape w/p
• Lathe centers: for holding long
jobs
• Chuck:
– 3 jaw chuck for circular or
hexagonal section
– 4 jaw chuck for irregular
shapes
– Magnetic chuck for holding
soft metal
 Mandrel: for
Mandrel holding hollow disc
shape w/p for
machining of side
faces

Collet: for holing

small diameter tool
and work pieces

Collet
 CUTTING TOOLS USED In a LATHE
¾ Single Point Cutting Tools
¾ Bit-Type Cutting Tools
¾ Form Tools (tapering and Threading Tool)

common cutting tool materials

™ For conventional machining processes, cutting
tool material must be at least 35% to 50%
harder than work material at the actual
temperature of machining
1. tool steels
2. high speed steel (hss)
3. cemented carbides
4. coated carbides
5. ceramics
6. cermets (ceramic material in a metallic binder)
7. sintered polycrystalline cubic boron nitride
(cbn)
8. sintered polycrystalline diamond (pcd)
MI-102: Manufacturing Techniques I. I. T.
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Geometry of
single point
cutting tool