ME2201 MANUFACTURING TECHNOLOGY I II year Mechanical Engg. A & B section Staff in-charage : A. Rajkumar, G. Baskaran A.P.

P./Mech Notes on Lesson UNIT I : THEORY OF METAL CUTTING Material removal process Types of machine tools Turning machines Drilling machines Boring machines Milling machines Grinding machines Shaping and planing machines Gear cutting machines Unconventional machining machines Special machines like automats, copy turning machines, reaming , copy milling machines, centreless grinding machine, broaching machine etc. Chip formation Discontinuous chip Continuous chip Continuous chip with built-up edge

Orthogonal cutting Mechanics of orthogonal cutting Merchants cutting force circle Orthogonal cutting with shear plane

Strain and strain rate in orthogonal cutting

Requirement of a cutting tool material Cutting tool materials Carbon tool steels High speed steel Cast cobalt alloys Cemented carbides Coated carbides Ceramics Diamond Cubic boron nitride(CBN)

Tool wear Tool life Taylors tool life equation Flank wear Crater wear Diffusion wear

Surface finish Ideal surface finish in turning Function of a cutting fluid o Cooling action o Lubricating action Types of cutting fluid Water based emulsions Straight mineral oils Mineral oils with additives 2 Cutting fluids

UNIT II : CENTRE LATHE AND SPECIAL PURPOSE LATHES Centre lathe constructional features Head stock Tail stock Bed Carriage Feed rod Lead screw Feed change gear box

Lathe specifications Distance between centers Swing over the bed Swing over the cross slide Horse power of the motor Number of speeds Number of feeds

Cutting tools Cutting tool geometry o Back rake angle o Side rake angle o End relief angle o Side relief angle o End cutting edge angle o Side cutting edge angle o Nose radius

Types of tools Parting tool Turning tool Right hand turning tool Left hand turning tool Radius turning tool Thread cutting tool Chamfering tool Internal turning tool Inter facing tool Recess or groove making tool Internal threading tool

Lathe operations Turning Facing Knurling Parting Drilling Boring

Taper turning methods Form tool method Compound rest method Tailstock set over method Using taper turning attachment

Thread cutting method

Special attachments Copy turning attachment Radius turning attachment

Machining time and power estimation

Capstan And Turret Lathe The principle parts are Comparison of capstan and turret lathe S.No. Capstan lathe Turret lathe 1. Short slide since the saddle is Saddle moves along the bed, thus clamped on the bed in position. 2. allowing the turret to be of large size. Light duty machine, generally for Heavy duty machine, generally for components whose diameter is less components with large diameters than 50mm. 3. as 200mm. Bed Head stock Cross slide and saddle The turret saddle and auxiliary slide

Too much overhang of the turret Since the turret slides on the bed, when it is nearing cut. there is no such difference.

Automatic lathes
Classification

Automatic lathes may be classified based on their Size Type of blank machined Processing capacity Machining accuracy obtained Principle of operation design features Number of spindles and work positions Type

Single spindle automates Cutting off Swiss type Automatic screw machine Special type

Multiple spindles automates Cutting off bar Drilling, forming, cutting off bar Bar Special type

UNIT-III : RECIPROCATING AND MILLING MACHINES Shaper The main parts of shaper are Base Column Table Ram Tool head assembly- tool feed handle, tool slide, apron, clapper box, tool holder Specifications Stroke length Length and width of table Number of ram double strokes per minute Motor horse power Range of ram speeds

Planer The main parts of planer are Bed Table Columns or housing Cross rail Tool head

Specifications

Dimensions of the table Horizontal distance between the two vertical housings Length that the table can travel Height from top of the table to the top of cross rail Type of drive Column and knee type o Horizontal o Vertical o Universal o Turret type Production type o Simplex o Duplex o Triplex

Types Of Milling Machine

Planomillers Special type o Rotary table o Drum type o Copy milling o Keyway milling o Spline shaft milling machine

Horizontal Milling Machine The basic parts of the horizontal milling machine are Base

Column Knee Saddle Table Arbor Over-arm Spindle The maximum length of longitudinal, cross and vertical travels of the table and its dimensions Main drive motor power Number of spindle speeds Distance from spindle nose to table surface

Specifications

Milling cutters Based on construction Solid Inserted tooth type

Based on mounting Arbor mounted Shank mounted Nose mounted

Based on rotation Right hand rotation Left hand rotation

Based on helix Right hand helix 9

Left hand helix

Plain milling cutters Side and face milling cutters Slitting saw Special form cutters End mills Methods of milling Upmilling (conventional milling) Down milling (climb milling)

Hole making operations The types of hole making operations performed on these holes are Drilling Boring Reaming Counter sinking Counter boring Tapping

Universal Drilling Machine(Radial Drilling Machine) The main parts are Base Column Radial arm Drill head

Salient features Provides movement of the spindle in three directions Several holes can be drilled on a work piece without moving the same.

UNIT-IV : ABRASIVE PROCESS, SAWING, BROACHING AND GEAR CUTTING Grinding wheel specification and selection Abrasive types Aluminium oxide Silicon carbide Cubic boron carbide Diamond

Grain size Bond Vitrified Silicate Synthetic resin Rubber Shellac Metal Fine Medium Coarse

Grade Structure Open Medium Dense Soft Medium Hard

Grinding wheel types Wheel balancing Dressing and truing Types of grinding machines Cylindrical grinding Surface grinding Centreless grinding

Cylindrical Grinding Machine The main parts are Base Tables lower and upper table Head stock Tail stock Wheel head

Surface grinding machine

Horizontal spindle and reciprocating table Vertical spindle and reciprocating table Horizontal spindle and rotating table Vertical spindle and rotating table

Centreless grinding machine The main parts are Grinding wheel Regulating wheel

Types of feed in centreless grinding Honing Honing is a low abrading process which uses bonded abrasive sticks for removing stock from metallic and non-metallic surfaces. The advantages of honing are Correction of geometrical accuracy Out of roundness Taper Axial distortion Infeed Through feed End feed

Dimensional accuracy

Lapping Lapping is generally the final finishing operation done with loose abrasive grains. The process is employed to get Extreme accuracy of dimension Correction of minor imperfection of shape

Refinement of the surface finish Close fit between mating surfaces

Super finishing Super finishing is another abrasive process which utilizes either a bonded abrasive like honing for cylindrical surfaces or a cup wheel for flat surfaces. It is generally used for Removing surface fragmentation Reducing surface stresses and burns and thus restoring surface integrity Correcting inequalities in geometry

Polishing and Buffing Polishing is done with a very fine abrasive in loose form smeared on the polishing wheel with the work rubbing against the flexible wheel. A very small amount of material is removed in polishing. In buffing the abrasive grains in a suitable carrying medium such as grease are applied at suitable intervals to the buffing wheel. Negligible amount of material is removed in buffing while a very high luster is generated on the buffed surface. The dimensional accuracy of the parts is not affected by polishing and buffing operations. Abrasive belt grinding In this process a continuous moving belt with an abrasive is used for grinding the surfaces. The abrasive belt is normally passed between two wheels with one being driven while the other remains idle. The workpiece is oscillated across the face of the abrasive belt to obtain a uniform belt wear and surface finish. Sawing machines The various types of sawing machines used are Hack saw 1

Manual Power Vertical Horizontal Contour

Band saw

Circular saw

Broaching Broaching is a multiple tooth cutting operation with the tool reciprocating similar to the sawing operations. The similarities end there, since in broaching the machining operation is completed in a single stroke as the teeth on the cutting tool called broach, are at a gradually increasing height corresponding to the feed per tooth of a milling cutter. Broaching machines Gear cutting Gear forming Vs Gear generation Gear shaping Gear hobbing Push broaching machines Pull broaching machines Surface broaching machines Continuous surface broaching machines

UNIT-V : CNC MACHINE TOOLS AND PART PROGRAMMING Numerical Control (N.C) It can be defined as a programmable automation in which the process is controlled by numbers, letters and symbols. Components of N.C o Program of instructions o Machine control unit o Machine tool N.C. Procedure o Process planning o Part programming o Tape preparation o Tape verification o Production Components Of CNC 1

A tape reader Micro or mini computer Computer hardware interface and servo mechanism Machine tool Greater flexibility High productivity Good reliability Metric conversions Memory functions

Advantages

Manual part programming Coordinate function Feed function Speed function Tool function Preparatory functions Miscellaneous functions Program number Tool length compensation Cutter radius compensation Canned cycles

Computer assisted part programming Preparing the part programs for CNC machine tools manually is a viable system for any kind of job. But the assistance of a computer is desirable for part programming because of a variety of reasons. The first and foremost in this respect is the complexity of the work piece which makes manufal part 1

programming a very difficult exercise. Close tolerance contouring to some mathematically defined, or through a set of points other than a circular arc, is an example requiring too many coordinate calculations making manual part programming too tedious to be practicable. APT language The complete APT part program consists of the following four types of statements Geometry Motion Post processor auxiliary